Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.

Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.

4.
Balboa Control Service ChecklistPreface System Components Required This manual is provided to aid the qualified service • Fuses (30 and 20A time delay plus 20, 10 and 3A)technician in troubleshooting and correcting problems • System Transformers (120 V and 240 Vfound in spas with M-7 Technology and control systems plus a 120 V Duplex)manufactured by Balboa Instruments, Inc. • System SensorsTools Required • System Panel(s) • System Circuit Board• Ammeter (50A)• Digital Multi-meter• Balboa Logic Jumper on a Stick Important• Balboa Six-in-one Screwdriver, Includes: Due to the danger of severe electrical shock, locate all power disconnects before servicing a spa. Precautions must Two Phillips Head and Two Flathead Screwdrivers Along be taken whenever working with breaker boxes, G.F.C.I.’s, or with a 1/4" and 5/16" Nut Driver service disconnects.• 5/ " Socket 16 Always refer to the wiring diagram which is included with• 1/ " Open End Wrench 4 each system on the inside of the system box cover. Use this• Small Wire Cutters diagram for voltage measurement points, and for proper• Pliers & Needlenose reconnection of wires. Pliers• Quick CheckTM Test Important Kit Be sure to bring the correct circuit board, topside control• Precision Thermometer - panel, components, and tools. Digital Fever Type• Padlock (to lock electrical Safety Tips disconnect during service) • Keep children and pets away.• Plumber’s Sealant • Be aware of your surroundings. Standing in water while repairing a spa puts you at serious risk. Quick CheckTM Test Kit • Avoid working in cramped or crowded conditions. Digital Fever Thermometer Balboa Logic Jumper on a Stick DANGER: SHOCK HAZARD. DO NOT PROCEED IF UNQUALIFIED IN WORKING WITH HIGH VOLTAGE.4 800.645.3201

5.
System DescriptionHighly advanced microprocessor technology has been combined with solid-stateelectronic switches to produce the world’s finest, high qualitystate-of-the-art digital control systems. Balboa control systems aretechnologically sophisticated, yet easy to understand, use, and troubleshoot.Topside Control Panel M-7 Sensors The control panel activates functions at the touch of a The two sensors located within the heater housingbutton. Each function will echo from the circuit board to the compare the inlet water temperature with the outlet waterLCD in a corresponding manner. The panel will also display temperature (regardless of water flow direction) todiagnostic messages which enable the service technician to determine the presence of water, low flow, temperatureeasily troubleshoot the system. limits, and operating temperatures. The system will automatically select the sensor that is exposed to the lowestCircuit Board temperature as the spa water temp controlling sensor. A typical circuit board has the following output The sensors in combination with specific software allowcapabilities: the spa to be controlled without the use of external pressure switches, flow switches, or temperature sensors.• 240 VAC System• Two-speed pump 240 VAC, 60 Hz, 2 HP• Single-speed pump 240 VAC, 60 Hz, 2 HP• Blower 240 VAC, 60 Hz, 2 HP• Heater 240 VAC, 60 Hz, 5.5 kW• Light 12 V, 12 W, 60 Hz, 1A or 120 V, 100 W In addition to these outputs, the board receives inputfrom the two temperature sensors located within the heaterhousing. Important Do not remove and replace the circuit board unless youhave tested all other components and proven that the circuitboard is actually causing the problem.www.balboa-instruments.com 5

6.
Wiring ChecksSafety is key when servicing any spa or spa control panel. Remember, safetycomes first for you and your customer. Please take all necessary precautionsbefore attempting any repairs. Wiring checks are the first step to ensure safetyand proper function before beginning service on a unit. Wiring Check Precautions System Box Wire Gauge Check• When working in a system box always be aware that it When inspecting the wiring for any control system, note may contain high voltage. that connections for the incoming wires are clearly labeled at• Always keep your fingers and hand tools away from any the main terminal block. wiring or circuit board when the power is on. Touching • 30A service – minimum ten gauge copper wire. anything in these areas can result in serious injury. • 40A service – minimum eight gauge copper wire.• All service calls, no matter how minor, should include • 50A service – minimum six gauge copper wire. a complete wiring check, beginning with the house breaker. These wires must connect the house breaker box, through the local disconnect, to the main terminal block. The wiring• Keep in mind, Balboa equipped spas only run on single diagram inside the system box shows the main terminal block phase electrical service. Three phase power will not as TB1. supply proper voltage to the system. Three phase power may overheat the pumps and cause the G.F.C.I. to trip. ImportantCheck for Loose Connections or Using non-copper wire can be dangerous, and also canDamaged Wires: be the cause of a spa’s malfunction. If non-copper wire• Make sure the power is off before you touch is used at any point, we do not recommend servicing the any wiring. spa until an electrician replaces it with the proper gauge• Once the power is off, carefully examine all wires for cuts copper wire. or defects. Important This service must be single phase. Any abnormal voltage reading requires an electrician. Do not attempt to fix these types of problems yourself. High voltage can seriously injure or kill. G.F.C.I. Wiring Check If a Ground Fault Circuit Interrupter has recently been installed, a majority of tripping problems can be attributed to incorrect wiring of the G.F.C.I. A clear understanding of the correct configuration is essential. Please refer to the figure on page 10 as needed.6 800.645.3201

7.
Wiring Check for G.F.C.I./Service Disconnect • From the neutral bar, locate the white load neutral, andImportant the green ground wire. The National • Be sure there are no other appliances on the spaElectrical Code states circuit. If there are, service must be re-wired to supplythat a service disconnect the spa only.breaker box (a G.F.C.I. • Make sure all four wires exit the house breaker box viacan be used for this conduit, routed to the G.F.C.I. breaker box. The blackpurpose) must be should be connected to the G.F.C.I. line-in 1. The redlocated at least five should be connected to the line-in 2. The white loadfeet away from the neutral connects to the neutral bar. The green groundspa and should be wire should be attached securely to the ground lug insideconveniently the G.F.C.I. box.located near theequipment bay. If it is not in G.F.C.I. Line-out Wiring Check forplain sight, keep the disconnect padlocked when in the offposition. 240 V Dedicated System (3 wire system including ground wire)Precautions The black wire should connect to load out 1, the red wire Effective January 1994, G.F.C.I.’s are required from load out 2, and the green ground wire should befor spa installations. Prior to that, G.F.C.I.’s had attached securely to the ground lug inside the G.F.C.I. box.been recommended for spa installations, but were All wires will exit the box via conduit routed to the spanot mandatory. control system. The white pigtail should be connected to the G.F.C.I. neutral bar. All wires will exit the box via If the spa you are servicing was not installed with a conduit routed to the spa control system. If the systemG.F.C.I., strongly urge your customer to improve safety and does not operate a 120 V component (ozone, musiccomply with current standards by installing one. equipment, etc.) then the white load neutral wire isNote: A suitable G.F.C.I. may be acquired through your local not required.distributor or Balboa Direct. G.F.C.I. Line-out Wiring Check Important! for 120/240 V Convertible System Remember, high voltage is still accessible in the house (3/4 wire system including ground wire)breaker box even though you have turned off the spa breaker. If the spa is equipped with a 120/240 V control system, an additional white load neutral wire must connect to theG.F.C.I. Line-in Wiring Check load neutral out. This wire runs with the others to the• Locate the proper circuit breaker and turn it off. system box. Proper placement of this neutral wire is• Remove the cover from the house breaker box. Check the essential. If miswired, the G.F.C.I. will trip when a 120 V main service amperage rating to the breaker box. device is activated.Note: Typically, a house circuit will require at least a 100Amp service when a spa is installed. Once you have found all wiring correctly installed,• From the circuit breaker, locate the red load wire and the begin to check for proper voltage. black load wire.www.balboa-instruments.com 7

8.
Voltage Checks - Breaker Box/G.F.C.I.When checking for proper voltage, please keep in mind that the acceptablevoltage range is + 10% of the recommended voltage. Acceptable voltage when120 V is specified as the desired voltage, is between 108 and 132 V. Acceptablevoltage when 240 V is specified as the desired voltage, is between 216 and 264 V. Important! G.F.C.I. Line-In Voltage Check This service must be single phase. Any abnormal voltage 240 V Dedicated System:reading requires an electrician. Do not attempt to fix • Be sure the spa circuit breaker (located in the houseproblems yourself. High voltage can seriously injure or kill. breaker box) is on.Breaker Box Voltage Check • Make sure the G.F.C.I. is off. • Probe the black and red wires. The meter should• Set your multi-meter or voltmeter for AC Volts. read 240 V.• Make sure the G.F.C.I. is off. • Probe the black wire and the green ground wire. The• Carefully turn on the spa circuit breaker. meter should read 120 V.• At the house breaker box, probe the spa circuit breaker • Probe the red wire and the green ground wire. This between the black and red wires. Your meter should should also read 120 V. read 240 V. • Turn on the G.F.C.I. breaker before continuing to the• Probe the black wire and the green ground wire. You system box. should see 120 V. Note: A white load neutral wire is not used in a 240 V• Probe between the red wire and the green ground wire. dedicated system. You should also see 120 V.• The voltage between the white load neutral and the green 120/240 V Convertible System: ground wire should be approximately 0 V. • Be sure the spa circuit breaker (located in the house breaker box) is on. • Make sure the G.F.C.I. is off. • Probe the black and red wires. The voltage should be 240 V. • Probe the black wire and the white load neutral wire. The voltage should read 120 V. • Probe the red wire and the white load neutral wire. The voltage should read 120 V. • The voltage between the white load neutral and the G.F.C.I. box ground lug should read approximately 0 V. • Turn on the G.F.C.I. breaker before continuing to the system box.8 800.645.3201

9.
Voltage Checks - System BoxG.F.C.I. Load Out Voltage Check System Box Check (at TB1)240 V Dedicated System: 240 V Dedicated System Check:• Be sure the house breaker is on. • Be sure the G.F.C.I. breaker is on.• Be sure the G.F.C.I. breaker is on. • Probe the black and red wires. Look for 240 V.• Probe the black and red wires at the G.F.C.I. load out 1 • Probe the black wire and the green ground wire for 120 V. and 2. The voltage should be 240 V. • Probe the red wire and the green ground wire – also 120 V.• Probe the black wire and the G.F.C.I. neutral bar. The • Recheck voltage under peak load conditions.* meter should read 120 V. 120/240 V Convertible System Check:• Probe the red wire and the G.F.C.I. neutral bar. The voltage should read 120 V. • Be sure the G.F.C.I. breaker is on.• Probe the black load out wire and the box chassis ground • Begin the voltage check at TB1. Probe the black and red lug. The voltage should read 120 V. wires. Your meter should read 240 V.• Probe the red load out wire and the ground lug. The • Probe the black and white wires. Look for 120 V. voltage should be 120 V. • Probe the black wire and the green ground wire – also 120 V.• Recheck voltage under peak load conditions.* • Probe the red wire and the green ground wire – again 120 V.120/240 V Convertible System: • Probe the red wire and the white load neutral wire. This should read 120 V.• Be sure the G.F.C.I. breaker is on. • Probe the white neutral wire and the green ground wire.• Probe the black and red wires at G.F.C.I. load out 1 and 2. This will show approximately 0 V. The voltage should be 240 V. • Recheck voltage under peak load conditions.*• Probe the black wire and the white load neutral wire. The meter should read 120 V. *Peak Load Check• Probe the red wire and the white load neutral wire for 120 V. It is important to check the voltage again under peak load conditions. To reach peak load, turn on the blower,• Probe the red load out wire and the box chassis ground heater, light, and all pumps. lug. Your meter should read 120 V.• Probe the black load out wire and the ground lug. The Peak Load Check for 240 V System: voltage should read 120 V. • Check the voltage between the black and red wires. The• Recheck voltage under peak load conditions.* acceptable voltage range is between 216 and 264 V. • Probe the black wire and the white neutral wire. This Important! voltage must be between 108 and 132 V. If the voltage is not within the acceptable range, call Peak Load Check for 120/240 Van electrician or the local electric company to diagnose Convertible System:the problem. • Check the voltage between the black and red wires. Acceptable range is between 216 and 264 V. • Probe the black wire and the white load neutral wire. The voltage must be between 108 and 132 V. • Probe the red wire and the white load neutral wire. The voltage must be between 108 and 132 V.www.balboa-instruments.com 9

11.
Basic Control System TroubleshootingLow Voltage replaced. Both F5 and F6 use a 25A time delay fuse. Only use a fuse of the same type and amp rating when you At Balboa, it’s been our experience that the majority of replace any of these fuses.the problems associated with electronic control systems are Elite Systemdue to low voltage. • Measure fingers 5 and 6 of the circuit board. You should see either 120V or 240V, depending upon the systemBrown outs configuration. “Brown outs” can have an effect on the spa’s operation in • If you determine that there is no voltage at fingers 5 anda variety of ways. The control panel may go blank, have 6, then the system power input fuse needs to bescrambled messages on the LCD, or only a few features will replaced. This fuse is located in the large fuse blockfunction. inside the system box. This configuration utilizes a 30A• If the system is getting the proper voltage at TB1, but still time delay fuse. does not operate, then test for a blown power input fuse. Note For All Systems: In each situation, the most likely If the system you are troubleshooting is a Prestige, reason for the system power input fuse to blow is a pump 2000LE M-7, Value M-7, or SUV System, the power input problem. However, on occasion, a blower problem may also fuses snap directly to the circuit board. cause this fuse to blow if a 10A blower fuse is not built in. Once the power input fuse has been changed:Checking the System Power Input Fuse • Probe the red wire and the white neutral wire. Again, voltage must be between 108 and 132 V. Warning • Check the voltage between the black and red These procedures are performed while the system is wires again. Acceptable voltage range is between 216powered up and running under peak loads. Be careful. and 264 V.SUV, Value M-7, 2000LE M-7, and These readings should be taken under peak loadPrestige Systems conditions.If your system uses 120V peripheral devices: Important• Measure between the white TB1 terminal and F5 power input fuse on the side farthest away from the circuit board If the voltage is not in the acceptable range, call an edge (opposite the F5 silkscreen). You should see electrician or the local electric company to diagnose the 120 volts. problem.• If the system is equipped with the additional F6 power input fuse, measure F6 in the same manner. You should also see 120 volts.If your system uses 240V peripheral devices:• Measure between the red TB1 terminal and F5 power input fuse on the side farthest away from the circuit board edge (opposite the F5 silkscreen). You should see 240 volts.• If the system is equipped with the additional F6 power input fuse, measure F6 in the same manner. You should also see 240 volts.• If you determine that there is no voltage at one or both locations, then the system power input fuse(s) need to bewww.balboa-instruments.com 11

12.
Troubleshooting (cont.)To Determine the Cause of a Blown Power Test the Amperage Draw:Input Fuse: • Turn off the power, disconnect the blower, make sure the Perform the following sequence of tests: pump is plugged in, and restore power.Test the System: • Start the pump and switch to high speed (if available), this should draw the most current.• Turn the power off. • Make sure all jets and valves are open.• Be sure to replace the system power input fuse with the • Check the amperage at the red pump wire. Compare same type. your reading with manufacturer specifications. (If the• Unplug the blower and all pumps. other plug-in devices exist, they should be tested in the• Restore the power and verify system operation. same way.)• If the fuse blows, then re-check the internal system wires • If the amperage draw and connector for burns, cracks or cuts in insulation. for each device is• If the fuse does not blow, turn the power off and plug in within manufacturer’s the pump. specifications, theNote: Be sure to test each device individually. problem could be a nuisance spike in theTest the Pump: pump, or water in the• Restore the power and activate the pump. blower.• If the fuse blows, there is a pump problem.• If the fuse does not blow, turn off the power.Test the Blower:• Plug in the blower.• Power up the system and activate the blower.• If the fuse blows, then there is a blower problem.• If the fuse does not blow, the combined pump and blower amperage may be excessive. To verify this, first check Note: These slow-blow fuses are not always discolored with your spa manufacturer for amperage draw limits on when blown. Always test continuity of a fuse with each device. an ohmmeter.• Since the blower should now be running, you can check Note: Miswiring of the spa is the most common reason for the amperage draw with an ammeter by measuring this fuse to blow. However, a lightning strike in the area is a around the black blower wire and compare with possible, though less likely, cause of the failure. manufacturer’s specifications.12 800.645.3201

13.
Troubleshooting (cont.)Test the Circuit Board Protection Fuse:SUV, Value M-7, 2000LE M-7,and Prestige Systems Transformer Installation RequirementIf your system has a white neutral line coming in from either (Applies to Elite and Prestige only; other systems haveyour service disconnect or GFCI installed into TB1: the transformer as a permanent part of the circuit board.)• Probe from the white TB1 terminal and one side of the Some symptoms of low voltage may be caused by circuit board protection fuse. The voltage should read the transformer. 120 volts. When working on a 120 V Elite or Prestige system,• Probe from the white TB1 terminal and the other side of double check to make sure the transformer has two the circuit board protection fuse. The voltage should read blue connectors. 120 volts. A 240 V transformer with one blue connector may beElite System installed by mistake in a 120 V system causing low voltage.• For a class 2 transformer circuit, UL requirements specify that a fuse must be permanently installed to protect the Confirm Transformer Connections: circuit board. Intermittent problems may occur when transformer• If you have determined that the system is getting connections are loose. Make sure your fingers are away from proper voltage through the power input fuse, then you exposed high voltage connections. Wiggle the transformer must check to see if the circuit board protection fuse wires near the connector on the circuit board. This will has blown. determine if there is a loose transformer connection or bad• First, turn off the power. Next, unplug the transformer pin on the circuit board. from the circuit board, then turn the power back on and • If the system intermittently turns on and off, turn the probe from the red TB1 terminal to one side of the fuse. power off.• The voltage should read 120 V or 240 V depending on • Plug in the test transformer, restore the power, and wiggle the system. the transformer wires again.• Probe from finger 5 to the other side of the circuit board • If there is no intermittent failure, no further analysis protection fuse. The voltage should read 120 V or 240 V is required. depending on the system. • Turn off the power and replace the transformer.• If either side has 0 volts, then the fuse is blown. If so, turn • After installing your test transformer, intermittent off the power and replace the circuit board. (See page 26.) symptoms may still occur during the test. If so,Note: Another, less likely reason for the circuit board replace the circuit board (see page 26) and installprotection fuse to blow is that a 240 V transformer was the original transformer.replaced with a 120 V transformer by mistake.• Make sure that the transformer is properly rated for the Important system. The voltage reading between fingers 5 and 6 on Be sure to turn the power off before replacing any the circuit board will determine the proper transformer component, especially a circuit board. input voltage for Deluxe and Standard models.• For a 120 V system, the transformer should have two blue connectors.• A 240 V transformer should have one blue connector.• If you determine that the circuit board protection fuse is not blown, this means that the transformer is receiving voltage.www.balboa-instruments.com 13

14.
Power-Up, Pump Priming and Software IDBefore applying voltage to the System, it is • Display will show “Pr” (or “Priming Mode” on Prestigevery important that you understand the Systems), indicating that the System is in a pump primingsequence of events that occur when power mode. During this mode the heater is disabled to allowis applied so that the pumps can be primed the priming process to be completed without theefficiently and faults created by no water possibility of energizing the heater under low flow or noflow can be prevented. flow conditions. Nothing comes on automatically, but the pump(s) can be energized by pushing all Jet buttons.Please review the following procedures andpower-up events before applying voltage to This mode will automatically last for about 4 minutes orthe System: you can manually exit the priming mode after the pump(s) have primed. (Manually exiting the priming1. Check the voltage at the main power panel to be sure that mode is described later in this text). Regardless of you have the correct voltage for the System being used. whether the priming mode is automatically terminated or Also, be sure that the voltage is within + or - 10% of the you manually exit the priming mode, the system will mean voltage. For 120V it should be between 108V and automatically return to the normal heating and filtering 132V. For 240V it should be between 216V and 264V. mode at the end of the priming mode.2. Test and reset the GFCI. If it does not operate properly, do • Pump Priming. As soon as “Pr” is indicated on the top- not apply voltage to the System until the problem has side panel, push all Jet buttons to start the pumps. On been corrected. models with a combined Jet button, push it until all3. Fill the spa to its correct operating level. Be sure to open pumps are on high speed. All pumps need to be running all valves in the plumbing system before filling to allow as in the high speed mode to facilitate priming. If the pumps much air as possible to escape from the plumbing and the have not primed after 2 minutes, and water is not flowing heater during the filling process. from the jets in the spa, do not allow the pumps to4. Vent air from the pump(s). Do this by loosening the continue to run. Turn the power off at the main power union nuts on the discharge of all pumps. Allow a small panel and repeat the process of venting the air from the amount of water and air to escape from the pump(s) and pump(s). (See step 4 on this page). After venting air from related plumbing. Retighten the union nuts. the pump(s) a second time, turn the power back on at5. Turn the power on at the main power panel. Depending the main power panel. This will initiate a new pump on which top-side panel the System is configured for, the priming mode. Sometimes momentarily turning the pump displays will go through specific sequences. During these off and on will help it to prime. Do not do this more than sequences, you will need to prime the pump(s) as 5 times. described in the following: Important: A pump should not be allowed to runThe following will occur: without priming for more than 2 minutes. Under NO circumstances should a pump be allowed to run• Display will show a series of numbers immediately without priming beyond the end of the 4 minute following Power-Up. On M-7 software created or updated priming mode. Doing so may cause damage to the since May 2001, this will be a series of four numbers. pump and cause the system to go into an overheat The first three numbers in combination are called condition. the Software ID. The three numbers in order are the Software Manufacturer ID, the Software Product Type ID, • After pump priming, push all Jet buttons to turn off the and the Software Version ID. Following the Software ID pump(s). will be either 12 or 24, indicating the heater wattage the • Next, manually exit the priming mode by pushing either software is configured for. There are differences in freeze the “Warm” or “Cool” button (the “Temp” button on protection between units that display a Software Version smaller panels). Note that if you do not manually exit the ID of 00 (or that don’t display a Software ID at all), priming mode as described above, the priming mode will versus units that display a Software Version ID of 01 or be automatically terminated after 4 minutes. Be sure that greater. the pump(s) have been primed by this time.14 800.645.3201

15.
Power-Up, Pump Priming and Software ID (cont.)• After you have manually exited the priming mode or the 6. After the System has been powered-up and the pumps system has automatically exited the priming mode, the have been primed, make a final voltage check at the top-side panel will momentarily display the set System terminal block. temperature and then dashes. • Voltage Check Note that the display is not showing the temperature yet. 1. Activate the low speed of the pump. This is because the system requires approximately 2 2. Adjust the temperature to turn on the heater. minutes of water flowing through the heater to determine 3. Activate any other equipment that does not turn the water temperature. the heater off.• After 2 minutes of water flowing through the heater the 4. Activate the light. temperature will be displayed. 5. Check the voltage. Push the “Warm” or “Temp” button to adjust the The voltage for 120V systems should be 108-132 between temperature to the desired setting. If the water line and neutral.. temperature in the spa is less than the set temperature, The voltage for 240V systems should be 216-264 between the heat indicator will turn on signifying that the heater either line and 108-132 between either line and neutral. has been energized. Note:• When the System is in the “Standard” operational mode If the voltage is not within tolerance while the System is it will automatically heat the spa and maintain it at the set operating as described above, turn off the power at the temperature. All user buttons will be functional. If a main power panel and correct the problem before higher temperature is desired, simply push the “Warm” continuing to operate the System. or “Temp” button until the desired temperature is displayed. (The maximum temperature setting is 104°F). Other energy-saving operation modes are selectable by pushing “Mode” (or mode button sequence).www.balboa-instruments.com 15

16.
Test Mode OperationSelecting Test Mode and Analysis • Pressing Mode toggles pump/blower/light timeouts off (displays “toOF" or "tF") and back on (displays "toOn" orDisplay Mode "tn"). When timeouts are off, ozone disabling on function• The software is in test mode when J43 is on 2 pins on the button presses is suppressed (but not retroactively to Elite, or when DIP switch 1 is ON on all models that have function buttons pressed before timeouts were turned off; a DIP switch at the edge of the circuit board. its thus suggested that timeouts be turned off as the first• Test mode may be entered and exited (by changing the action after powering up the spa). This setting is not jumper or switch setting) at any time (no need to cycle saved upon power down. NOTE: Even though the main power). purpose of turning timeouts off is to disable timeouts on manual pump/blower/light turn ons – on some models,• The software goes into analysis display mode when in test leaving timeouts off can make a pump run mode and the light is on (at any intensity, if light is "forever" once its turned on automatically in dimmable). certain situations. For this reason, its imperative Note that on models where the light button is combined that the spa never be left in test mode for the user. with the pump button, it is not possible to go into analysis And if youre unsure as to whether you turned display mode without the pump running. timeouts off or not in test mode, its safest to exit test mode and then cycle power on the spa.Differences in the display when in testmode (but not in analysis display mode) On panels which cannot display a letter such as F or C after the temperature:• In standard mode (circ or non-circ), temperature shimmers when not current. In test mode, the character that would be shown to the• In economy mode (circ or non-circ), temperature right of the temperature (A, b, F, C, E, or P) is instead shown shimmers when not current, and is always displayed with for a split second before the temperature its for, with an "E" instead of "F" or "C". equal sign (=) to the right of it. For example, instead of 105A alternating with 104b, youll see A= followed quickly by• In sleep mode (circ or non-circ), temperature shimmers 105 alternating with b= followed quickly by 104. when not current, and is always displayed with "P" instead of "F" or "C".Differences in the display when in analysisdisplay mode:• On the Elite: Whether in standard, economy, or sleep mode (and circ or non-circ), temperature display alternates between displaying "temp" connector sensor temperature with "t" instead of "F" or "C" and "high limit" connector sensor temperature with "H" instead of "F" or "C". (These sensors are not actually serving different "temp" versus "high limit" functions; the labeling on the circuit board simply predates M7 nomenclature.)• On all other models: Whether in standard, economy, or sleep mode (and circ or non-circ), temperature display alternates between displaying "A" connector sensor temperature with "A" instead of "F" or "C" and "b" connector sensor temperature with "b" instead of "F" or "C".16 800.645.3201

17.
Topside Control Panels Available for the Available for the Elite SUV and Value M-7 Heat Lite Duplex Blower Jets System Temp Light Electronic Spa Controls Deluxe Panel Available for the Elite and 2000LE M-7Preliminary Panel Check Bulb Replacement• If the problem is not obvious, look on the topside Another panel problem may be burned out backlighting control panel for diagnostic messages. bulbs. These bulbs can easily be replaced. If no messages are seen, run through all spa functions • With the power off, gently pry up the topside control and note any inconsistent operation. panel with a screwdriver. Next, locate the gray bulb holes• If diagnostic messages appear on the topside control in the back of the panel. Use a screwdriver to twist the panel, see page 19 for troubleshooting tips. bulb approximately 1/4 turn to remove and replace theOnce you have determined that proper voltage is running bulb. (Needlenose pliers may also be useful.)through the circuit board and transformer, continue to thetopside control panel. A panel that is not functioning Remote Panel Troubleshootingproperly may include the following symptoms: low voltage Remote panel applications need special considerationsuch as missing or scrambled segments, missing icons on where the panels connect to the circuit board.the LCD, non-functional LED’s, or nonfunctional buttons. Ifany of these symptoms are present, perform the following: If You are Working on a Spa With a• Turn the power off and unplug the panel from Remote Panel: the circuit board. • Before replacing the circuit board or any panel, remove• Then, plug in your test panel and restore power. If the gang connector from the system box and plug each everything functions normally, replace the topside panel. panel into the circuit board directly and individually. Test• If you still see symptoms of low voltage, such as a all functions with each panel separately. sluggish, blank or partially blank panel, or if the display If a Remote Panel Doesn’t Work: or the LED’s do not function at all, turn the power off; • Remove the remote panel from its location. reset the battery backup (if applicable); unplug the ozone generator (if equipped); then restore power to the • Be sure to secure the end of the panel cable. system. If the problem persists, turn off the power and • Plug the remote panel directly into the board. This replace the circuit board. removes the extension loom with its one-to-one connector from the circuit board and will help you determine whether you have one panel with a problem, a defective gang connector, a bad extension loom, a bad one-to-one connector, or a circuit board problem.www.balboa-instruments.com 17

18.
Topside Control PanelsAvailable for the Prestige These bulbs can easily be replaced.Preliminary Panel Check • With the power off, gently pry up the topside control panel• If the problem is not obvious, look on the topside with a screwdriver. Next, locate the gray bulb holes in the control panel for diagnostic messages. back of the panel. Use a screwdriver to twist the bulb If no messages are seen, run through all spa functions approximately 1/4 turn to remove and replace the bulb. and note any inconsistent operation. (Needlenose pliers may also be useful.)• If diagnostic messages appear on the topside control panel, see page 19 for troubleshooting tips. Remote Panel Troubleshooting• Most error messages are stored in the fault log. To view Remote panel applications need special consideration the fault log, the spa must be in test mode and the spa where the panels connect to the circuit board. light must be turned on. (See page 22)Once you have determined that proper voltage is running If You Are Working on a Spa With athrough the circuit board and transformer, continue to the Remote Panel:topside control panel. A panel that is not functioning • Before replacing the circuit board or any panel, plug eachproperly may include the following symptoms: low voltage panel into the circuit board directly and individually. Testsuch as missing or scrambled segments, missing icons on the all functions with each panel separately.LCD, non-functional LED’s, or nonfunctional buttons. If anyof these symptoms are present, perform the following: If a Remote Panel Doesn’t Work:• Turn the power off and unplug the panel from • Remove the remote panel from its location. the circuit board. • Be sure to secure the end of the panel cable.• Then, plug in your test panel and restore power. If • Plug the remote panel directly into the board. This everything functions normally, replace the topside panel. removes the extension loom with its one-to-one connector• Disconnect ozone generator (if applicable). from the circuit board and will help you determine• If you still see symptoms of low voltage, such as a whether you have one panel with a problem, a defective sluggish, blank or partially blank panel, or if the display gang connector, a bad extension loom, a bad one-to-one or the LED’s do not function at all, turn the power off; connector, or a circuit board problem. reset the battery backup (if applicable); unplug the ozone • Gang connectors cannot be used on the first three jacks generator (if equipped); then restore power to the (i.e., on Millennium panel jacks). system. If the problem persists, turn off the power and • The first three jacks are functionally identical. Try the replace the circuit board. panel in another one of these jacks.• Press “Warm” and “Cool” simultaneously to access the • The two aux panel jacks are functionally identical. performance analysis mode. (See page 23) • If multiple panels work in one jack but not another jack (of the same set), the problem is most likely with theBulb Replacement controller board. Another panel problem may be burned out back-lighting bulbs.18 800.645.3201

19.
Panel MessagesPanel messages are a quick clue toward and allow the water to cool to below 108° F. Addingsolving a variety of problems. Here are the cool water may be necessary. Touch any button to reset the system. If the water is still hotter than themost common messages and what they mean: set temperature, press the blower button (if applicable) to cool the spa.The Panel Displays: If the Problem Recurs, test the Sensor Set. (See page 21) , , or (At least one of the sensors has detected water The Panel Displays: temperatures of 118ºF inside the heater.) , , , ororThe Panel Displays: or , , or The Panel Displays: (One of the sensors has detected the temperature of the , , , or water coming into the heater to be 110ºF, and so the water in the spa is likely to be that hot.) These indicate that the spa has shut down due to an This indicates that the spa has shut down due to an overheat situation: open or faulty sensor:Note: Overheating may occur if the low-speed pump is set to If the problem recurs, test the sensor set. (See page 21)operate for extended periods of time, or if the incorrect Note: In rare cases, rapid system overheat causes sensorpump is installed. In rare cases (usually warmer climates), error messages. Be sure to rule out possible situations likethe circulation pump may also cause overheating. no flow or no water.The following is a list of most probable causes of thismessage. Inspect these first: The Panel Displays: • Check slice or ball valves. Make sure that they , , or are open. • Make sure the correct pump is installed. This indicates that the sensors are out of balance. • Clean the filter/skimmer if there is any blockage. If alternating with temperature, it may just be a temporary • Check heater element alignment. condition. If flashing by itself, spa is shut down. • Check for debris on the heater element. If the panel also displays “Service Reqd,” spa is shut down. • In extremely hot weather, check for proper If the spa shuts down due to this error, one (or both) of cabinet ventilation. the sensors are probably reading several degrees off. If the • Make sure the temperature sensor is fully inserted problem recurs, test the sensor set. (See page 21) into the sensor fitting on the heater. • Check for excessive filter duration. The Panel Displays:Note: A common programming mistake is overlapping filtertimes that may cause the spa to filter continuously. , , or • Check the water level. This indicates that a sensor detects a possible freeze • Check the water temperature with an accurate condition. temperature thermometer. Remove the spa coverwww.balboa-instruments.com 19

20.
Panel Messages (cont.) This message does not appear on M-7 software showing Any time the lower of the two temperature sensors goesa Software Version ID of 01 or greater. below 45°F, all pumps/blowers turn on. They continue to run This is a normal spa function; no further action is for 4 minutes after the temperature reaches 45°F or above. As soon as the temperature falls below 45°F again, thisnecessary. process restarts. This “simplified” sensor freeze protection When either sensor reads below 40° F, the system functions at all times, even when another fault conditionprovides freeze protection. It automatically activates the (other than total sensor failure) has occurred and haspump (and the heater if necessary) to circulate the water and otherwise shut the spa down.warm the plumbing. The equipment stays on until the sensorsdetect that the spa temperature has risen to within 15ºF of the The Panel Displays:set temperature. The other pumps and the blower will purgefor 30 seconds to 2 minutes at the end of the freeze , , orcondition. If pump 1 was turned on due to this reason alone, This indicates that a substantial difference inthis message will appear for up to two minutes right after temperature between sensors has been detected duringvery cold water is detected. heating. This could indicate a flow problem. Check water level inNote: Internal freeze protection only functions when there is spa. Refill, if necessary. If the water level is okay, make sureproper power running to the spa, and the control system is the pumps have been primed.operational. Using an optional freeze sensor may benecessary in extreme climates to prevent plumbing damage, On the fifth occurrence of the above message the panelbut will only work properly if placed inside the spa skirt in will display:the coldest area.All spa models are different in shape and size and have , ordifferent thermal characteristics; therefore, Balboa This indicates a persistent flow problemInstruments, Inc. cannot be held responsible for freezedamage to the spa’s plumbing. Testing is the responsibility The heater is shut down while all other spa functionsof the spa manufacturer and must be done to determine continue to run normally. Power on the spa must be cycledthe best location for the freeze sensor. before the heater will function again.The Panel Displays: The Panel Displays: , , or , , or This indicates that the auxiliary sensor detects a possible freeze condition. This is a normal spa function; no further action is necessary. When the auxiliary sensor reads around 40°F (actual This indicates that there is not enough water in thetemperature dependent on specific auxiliary sensor used), heater. Spa shuts down for 15 minutes.the system provides freeze protection. It automatically This could indicate poor flow or air bubbles in the heater.activates all of the pumps and the blower to circulate waterand warm the plumbing. On the third consecutive occurrence of the above message (without a successful heating cycle in between) the panelNote: This auxiliary freeze protection functions at all times, will display:even when another fault condition has occurred and hasotherwise shut the spa down. , , or This message can also indicate “simplified” sensor freeze protection in progress (on M-7 software showing Spa is shut down and will not reset in 15 minutes. Press a Software Version ID of 01 or greater), which behaves any button to reset manually. as follows: continued on page 2220 800.645.3201

21.
Panel Messages (cont.) Testing the Sensor Set cup of warm water (ideally above the set temperature, so the spa wont try to heat 1. Check sensor wires for cracks or damage that may during this test, as there is no heater indicate the presence of a rodent. protection during this test) and verify that they read the same temperature 2. Inspect the connections of both sensors on the circuit (within 1°F/0.5°C). board. The plugs must be clean. • If the problem is solved, replace the sensor 3. If the sensors are not totally failing but are showing set. If the problem is not solved, do not excessive (2° F / 1.0 °C or more) difference between replace the sensor set. the two sensors when not heating (a possible cause of Sn/SnS/SENSOR SYNC, HL/HFL/HTR FLOW LOW, and • Plug in the original sensor set to verify that there is LF/LOW FLOW messages), do the following: not a connection problem. • Note which sensor is reading consistently higher • If the problem continues after following the above (A vs B or t vs H). steps, then replace the circuit board. 4. Unplug the two sensors from the circuit board and 8. If you cannot get readings of the sensors on the interchange them (ie, plug the one that was in the topside panel even in M7 Test Mode / Analysis Display A or t jack into the B or H jack and vice versa). Mode (for example, because the system always 5. Press a panel button if any "stray" faults appeared indicates an Overheat condition when it shouldn’t): during the process. (Stray fault are normal when • You can use an ohmmeter to evaluate the validity sensors are unplugged then plugged back in while of each sensor independently (after unplugging the the system is running.) sensors from the circuit board). 6. Within a minute or so*, see if the same or other • You will need sharp tips on the meter probes(or a sensor is now reading consistently higher: Balboa Logic Jumper on a Stick) to be able to • If the same sensor (A vs B or t vs H) is make contact with the little bit of metal of each of reading higher after the sensor interchange, the two sensor wires visible through a window on the problem is on the circuit board. Replace the connector. the circuit board. • The following chart shows what temperatures • If the opposite sensor is now reading higher, the certain resistance values translate to: problem is with the sensor(s). Replace the sensor set. 1.5k 231F 110.5C 14.7k 108F 42.5C * If you wait more than 2 minutes after 3.0k 190F 88.0C 15.4k 106F 41.0C plugging the sensors back in, heating may 5.0k 162F 72.0C 16.2k 104F 40.0C start (even outside a filter in Economy or 7.0k 144F 62.5C 17.2k 101F 38.5C Sleep mode) due to a stray Cd/CLd/COLD 9.0k 131F 55.0C 18.1k 99F 37.0C WATER condition usually detected when 10.0k 126F 52.5C 20.2k 94F 34.5C sensors are being plugged in while the 11.1k 121F 49.5C 25.5k 84F 29.0C system is running. 11.7k 119F 48.5C 30.0k 77F 25.0C 7. If there is a message indicating an open or faulty 12.1k 117F 47.5C 40.0k 65F 18.5C sensor: 12.7k 115F 46.0C 55.0k 53F 11.5C • Unplug the sensor set (but leave the original 13.2k 113F 45.0C 95.0k 32F 0.0C sensors in the heater) and plug in the test 13.6k 112F 44.5C 184.0k 9F -13.0C sensor set. Put both sensors into the same 14.1k 110F 43.5C 320.0k -9F -23.0Cwww.balboa-instruments.com 21

22.
Panel Messages (cont.) Prestige Fault LogThe Panel Displays: Every time the Prestige goes into a condition correlating -- ,-- ,-.- or - - to one of the following messages it records the message and information. The most recent 24 such conditions are stored This indicates that the temperature is completely (if a 25th such condition occurs, it is stored and the oldest of unknown because the pump has not yet run for 2 the previous 24 is forgotten). minutes after Priming Mode was exited. This is only displayed for 2 minutes at power-up. Messages logged:The Panel Displays: This indicates that the IC chip used to store batterybackup information cannot be communicated with. It may be a problem with the chip itself or a problem withthe interconnections to that chip. Replace the circuit board.Some Troubleshooting Scenarios1. You find out the system is in “OHH.” This alone doesnt explain a lot. What led up to the “OHH” is much more important. If its a Prestige, review the fault log carefully. Otherwise, see if the user has any additional information (for example, how long before the “OHH” was the spa panel last checked, and how hot was the water then). If the spa has cooled, see whether the problem can happen again, this time watching carefully to see if there are additional clues leading to the “OHH” (for example, other messages that appear shortly before the “OHH” happens).2. You find out the system keeps showing “HFL,” or is now in “LF,” or is shut down due to a "dry" fault. Put the spa in test mode with the light on, so that you see the two sensor temperatures. Are they normal (within 1°F / 0.5°C) when not heating? How far apart are they when heating? “HFL” happens when they are 6°F / 3°C apart (4°F / 2°C on 120V and other low-heater-wattage Information stored for each event: systems), see how quickly that happens after heating Message displayed starts. If its getting close to that right away, its probably a “Days ago” count consistent flow problem, but if its nowhere close to the Actual hour “HFL”-causing temperature difference, the flow problem may be intermittent or only occur in certain specific Actual minute situations. Mode (Standard, Economy, Sleep) Set temperature Sensor A temperature Sensor B temperature22 800.645.3201

23.
Panel Messages (cont.)To View the Fault Log: • Make sure the system is in test mode with the spa Performance Analysis Mode (Prestige Only) light turned on. The panel has a built-in ability to display information • Press the “Up” button to cycle through the last 24 about the reliability of its communication with the fault messages (oldest first). motherboard. - The display reads Ft01 through Ft24 and the Performance Analysis Mode is toggled by pressing the normal message for that fault. “Up” and “Down” buttons simultaneously. - Power cycling events will be indicated by a (It comes on automatically for the first 15 seconds “PRIMING MODE” message. after power up, then turns off, but can be turned on by the user at any time.) - The mode in effect at the time of the fault flashes while information for that fault is being In the performance analysis mode, the top line doesn’t displayed (not valid in the case of a power display the normal text messages, but instead shows a cycling event). constantly updated text line in a two hexadecimal digit format as follows: - After the “Up” button has been pressed 24 times to show all the stored events, the display reverts 00.00.00 99 45 (sample line) back to normal test mode. BC.W1.W2 LW GC (explained below) • Press the “Down” button to view information on BC = How many times the CRC on the received each fault. packet turned out bad - The first press will display “...DAYS AGO” and the W1 = How many times the first byte of a packet time the fault started. was wrong - The second press will show “SET TEMP WAS” W2 = How many times the second byte of packet with the set temperature shown. was wrong - The next press of the “Down” button will LW = The last wrong first byte of a packet display “SENSOR A WAS” with the Sensor A GC = How many times the CRC was good temperature displayed. - The next press will display “SENSOR B WAS” Summary: If communication between the panel and the with the Sensor B temperature displayed. motherboard is good, the rightmost value should be - Power cycling events show partly valid* “DAYS AGO” changing constantly and the other values should change data but invalid time and temperature data. only a few times a minute at most in bursts, and even less *There is one day added to the fault log for each power often in the long run.cycling. The system does not keep track of how many daysthe power was actually out for. Note: To avoid confusing the display, you cannot press “Time” or “Mode” buttons while in the middle of viewing the fault log. Pressing “Up” while programming time settings will not bring up a fault display log. Interpretation of fault messages is best done in context.It may be helpful to write down the information you see ateach step while viewing the fault log. Information such astemperature at the time of the fault and what kind of faultmay have come before and after is most helpful indiagnostic situations.www.balboa-instruments.com 23

24.
G.F.C.I. TroubleshootingKeep in mind that a majority of G.F.C.I. tripping problems can be attributed toincorrect wiring. G.F.C.I. troubleshooting usually finds the problem.If Correct Wiring is Verified To Disconnect the Heater• Check to see if the proper G.F.C.I. is installed. • First, turn off the main circuit breaker, then remove both• Check the label in the system box near TB1 to determine heater straps or wires from the system heater output, not the maximum amperage draw for the system. the heater itself.• Be sure the G.F.C.I. is rated for more amperage than the • After restoring the power, try to reset the G.F.C.I. again. If system will draw. it no longer trips after the system calls for heat, then• For a 240 V dedicated system, a 2-pole G.F.C.I. with no replace the heater. load neutral is acceptable. • If the G.F.C.I. still trips, look for pinched or shorted wires• For a 120/240 V system, the G.F.C.I. must include a load at the transformer. Make sure that the screws that attach neutral out. the transformer to the system box have not pinched or damaged the insulation of the transformer wires.• If the white load neutral wire is routed from the G.F.C.I. neutral bar directly to TB1 in the system box, then the • If the transformer wires are undamaged, check for any G.F.C.I. will trip when a 120 V device is activated. other pinched wires. Refer to the wiring diagram to verify the correct wiring of the control system.• For a detailed wiring checklist, please review the previous segment of this manual on proper G.F.C.I. wiring or the • If everything looks to be in perfect working order, then G.F.C.I. manufacturer’s instructions. the G.F.C.I. may be defective.• If the wiring is correct and the G.F.C.I. will not reset, then unplug the pump and try to reset the G.F.C.I. If the G.F.C.I. trips again, then unplug the blower and reset the G.F.C.I.. If the G.F.C.I. continues to trip, then do the same procedure for the ozone generator.• If the G.F.C.I. stops tripping after you unplugged one of the spa’s components, turn off the power to the spa then Ground-Fault Circuit Interrupter/Circuit plug in each component except the one that tripped the Breaker (GFCI) G.F.C.I.• Power up the system. If the G.F.C.I. no longer trips, then you have correctly identified the problem. Repair or replace the component as instructed by the spa manufacturer.• If you have unplugged all of the spa’s components and the G.F.C.I. still doesn’t reset, then the problem is most likely a ground fault in the heater.24 800.645.3201

25.
Testing the Circuit Board OutputTesting the Circuit Board Output • Probe these connections at the circuit board after activating the function with the topside control panel. If your topside control panel is working properly, but a • If you do not have correct voltage, double check the inputpump, blower, or other device does not activate when its voltage before you replace the circuit board.panel button is pressed, further diagnosis is easilyaccomplished with the Balboa Quick CheckTM. • If you do have correct voltage at the circuit board, turn off the system power and check for a blown in-line fuse. Blowing the in-line fuse or the power input fuse is usually a symptom of a faulty pump, blower, or a short in the wiring to one of those devices. • If the fuse is good, then replace the output connector. • If the high-speed pump comes on when the system calls for heat or when the system goes into a filter cycle, the pump is most likely wired backwards. Verify that the black (low speed) and red (high speed) wires are not switched in the amp connector or the pump itself. • Always check to make sure all devices are plugged into the proper location. Note: If the spa light output is not detected with the Balboa Quick CheckTM Test Kit Quick Check, be sure to check continuity of the light fuse on the circuit board.To use the Balboa Quick Check:• Turn off the power at the house breaker box.• Unplug the device in question, and plug the Quick Check in its place.• Restore power to the spa and press the appropriate panel button again. If the Quick Check’s light appears, the device in question is receiving voltage.• An ordinary multi-meter can also be used to check for proper output voltage, except when working with a variable-speed blower or a dimmable spa light. In these cases, a component on the circuit board called a “triac” needs to be under a small load to test output voltage.Note: If a small load is not applied to these systems,voltage indications of up to 240 volts AC can be seenwhen measuring output voltage, even if the component isnot activated.• Even if the system is not equipped with a blower triac, the best way to verify voltage output is with the Balboa Quick Check.• If the Quick Check light does not appear after pressing the appropriate panel button, trace the wires from the corresponding connector in the system box back to the circuit board.www.balboa-instruments.com 25